Integrated medical device

ABSTRACT

There is herein described light emitting medical devices and a method of manufacturing said medical devices. More particularly, there is described integrated light emitting medical devices (e.g. neural devices) capable of being used in optogenetics and a method of manufacturing said medical devices.

FIELD OF THE INVENTION

The present invention relates to light emitting medical devices and a method of manufacturing said medical devices. More particularly, the present invention relates to integrated light emitting medical devices (e.g. neural devices) capable of being used in optogenetics and a method of manufacturing said medical devices.

BACKGROUND OF THE INVENTION

Electrical probes for neural stimulation have been in existence for some time. The study of optogenetics requires illumination of selected areas of treated tissue with light of a specific wavelength and the ability to record the responses of neuron activity in the area. Probes have been developed which allow illumination of an area of tissue by the incorporation of an optical fibre waveguide or an integrated waveguide.

Prior uses of optogenetics have been demonstrated using optical fibres illuminated from a remote source. The remote source typically used is either a relatively expensive laser or a macro LED, the latter having a low optical coupling efficiency, such that only a small fraction of the light is delivered to the fibre. The light emitted from optical fibres is neither collimated nor focussed but, as the numerical aperture of the fibres is typically quite low the light output required (power density) to elicit a response is modest. This has some advantages but the construction of these hybrid probes is prohibitively expensive. Additionally, the spacing between the light source and receptors is not controlled. Typically, only one fibre from an external light source is available on each hybrid probe as the shank width is too small to accommodate multiple fibres. This restricts the emission to one wavelength at any given time, making simultaneous stimulation and inhibition difficult. The fibre is typically placed far away from the probe distal end and light is directed in the direction of the distal end where the sensors are placed so that there is illumination across the detector elements. Consequently, this leads to non-uniform illumination at varying sensor positions (absorption and scattering of the incident light) and optical artefacts caused by the incident light shining on the detector. A possible mechanism to improve this is to etch a hole in the Si probe and placement of the fibre inserted in a trench on the probe backside with a 45° angled facet so that the light is directed out of the plane of the probe. However, this is prohibitively expensive and only very skilled labour would be in a position to fabricate such a structure.

In US 2011/0087311 there is a microstructure probe for delivering light of variable colour and/or power, via a set of integrated light guides, from a source (or set of sources) to regions spatially arranged 3-dimensionally, with a length scale of microns to millimeters. In exemplary embodiments of this invention, a microstructure probe comprises many lightguides and is adapted to be inserted into neural or other tissue. The lightguides run in parallel along at least a portion of the axis of the probe. US 2011/0087311 is incorporated herein by reference.

Most optogenetics activate or silence large populations of a given cell type or pathway. It is therefore a preferred feature of the present invention to provide a neural probe which will enable improved resolution of location between emitter to emitter and emitter to sensor and sensor array. This will greatly increase the power of optogenetics to understand neural activity patterns in brain functions.

It is an object of at least one aspect of the present invention to obviate or mitigate at least one or more of the aforementioned problems.

It is a further object of at least one aspect of the present invention to provide an improved neural probe.

It is a further object of at least one aspect of the present invention to provide a method of manufacturing an improved neural probe.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided an integrated light emitting neural probe, said integrated light emitting neural probe comprising:

a base region within which there are integrated connection points which are capable of connecting to other electrical components;

extending from the base region there is an integrated elongate probe with a distal tip;

one or more light emitters located in the region of the distal tip of the integrated elongate probe; and

one or more integrated detectors.

The present invention therefore relates to medical devices such as neural probes made from at least one integrated light emitter and detector. The neural probes comprise a probe structure and a light emitter of an integrated solid state construction. Optionally, the integrated light emitter may be a monolithically integrated light emitter.

It should be noted that the integrated light emitting neural probe of the present invention is not a waveguide.

The integrated light emitting neural probe may be used in a range of optics situations such as optogenetics.

The integrated light emitting neural probes of the present invention may therefore be used for the illumination of selected areas of treated tissue with light of a specific wavelength or band of wavelengths extending from UV to near IR. The neural probes have the ability to record the responses of neuron activity in the probed area.

The neural probe may have the general structure of a needle-like probe and may be formed from a variety of structures such as gallium nitride on a silicon carrier or gallium nitride on a sapphire carrier.

The shape of the neural probe may be of any suitable shape capable of sub-dermal insertion with minimal tissue damage.

Alternatively, the probe structure may also comprise an indium gallium arsenide and/or aluminium gallium arsenide diode structure that may or may not be supported by a carrier such as sapphire or silicon. Other suitable materials are zinc selenide or gallium phosphide.

The shape of the neural probe may, for example, be cut from the emitting material on the carrier such as sapphire using a laser cutting tool.

By selection of the appropriate gallium nitride material the output wavelength can be accurately defined for each application.

The light emitter may also be shaped to allow collimation, focussing or another means to increase the light emission extraction.

A substrate forming the integrated light emitting neural probe may also carry sensing elements integral to the probe formed at predetermined gaps from the light emitter. Multiple emitters and sensor probes may be constructed at predetermined gaps on a single probe. Emitters of differing wavelengths are also possible through monolithic integration or other means.

The integrated elongate probe may have any appropriate length such as about 100 mm.

The light emitter may be located towards or on the distal tip. The emission wavelength may be out with the visible range.

The light emitter may be any suitable light emitter and preferably an LED. There may be one or more LEDs located on the integrated elongate probe.

The neural probe may be designed to integrate single or multi-excitation and single or multi-detection schemes. Furthermore, the neural probe may be designed to reduce detection of artefacts and at the same time to prevent electrical crosstalk and parasitic capacitance effects. This is possible by having an electrically conductive blocking layer which has the dual function of being a ground plane or two layers, one of which is an electrically conductive ground plane. This can be patterned to minimise overlap with the sensing structure with the other layer being an opaque layer which may or may not be insulating. Furthermore, novel lensing or re-direction of the light may be provided to improve directionality of the light to both reduce artefacts and to increase the power density or increase the extraction efficiency to allow for lower drive currents.

The neural probe may also comprise electrodes for sensing which are integrated into the structure. The neural probe may therefore comprise sensing elements.

The sensing elements may be shielded from direct exposure to the emitting element by a blocking layer. The blocking layer may also be electrically conductive and designed to act as a ground plane. A separate ground plane can also be formed and a separate insulating plane used to provide shielding from the LED drive to minimize optically induced cross-talk via effects such as the Becquerel effect. The ground plane may be designed to have an effective area which results in an effective capacitance of <100 pF between the ground and the detector electrode. The ground plane can also be designed to have features such as cross-hatch to reduce the plate area and therefore the effective capacitance between the sensing detector and ground.

The blocking layer may also be designed to have a thickness where the dielectric value minimises the parasitic capacitance.

The sensing elements may also be designed to reduce electrical cross talk and parasitic coupling effects from the electrical drive signal for the light emitting element to the electrical sensing detector.

The sensing elements may be at discrete sites placed at a known distance from the source.

The sensing elements may be ring shaped detectors surrounding the source in order to ensure uniform detection and reduce capacitance by having a smaller area, allowing higher packing density.

The emission wavelengths are typically but not limited to about 300-1500 nm and preferably about 470 nm for optogenetic stimulation.

The emission wavelengths are typically, but not limited to about 300-1500 nm and preferably about 590 nm for optogenetic inhibition.

The probe structures may be encased in silicon nitride/silicon dioxide films or another suitable material for biocompatibility.

Multiple emitters and sensor groups may be present on each probe.

The LED structure may include a lens or other device to collimate or focus the light output.

The LED structure may include an emitter shaped to increase the light extraction efficiency.

The neural probe of the present invention may therefore comprise a blocking layer which is capable of suppressing Becquerel effects in a sensor array. The blocking layer may be composed of, but is not restricted to aluminium. A metallic or other electrical conductive layer can be used in order to shield the sensor array from electrical coupling effects such as capacitive coupling from pulsed switching of the LED. In one embodiment the ground plane may be constructed as a lattice or a grid in order to minimise overlapping area and unwanted capacitance between the LED drive and probe sensing circuits.

An oxide layer or similar insulating layer is used to encapsulate the blocking layer and isolate it from the sensor array. Sensor metal arrays are defined on top of this insulating layer. The sensor metal can be, but is not restricted to iridium, gold, platinum or titanium or a combination of metals. While biocompatible metals should be chosen, it is also possible that the sensor array may be encapsulated with a biocompatible material such as, but not restricted to silicon nitride or polyimide. In this case the sensor recording sites should be exposed using an appropriate lithographic process.

According to a second aspect of the present invention there is provided a method of manufacturing an integrated light emitting neural probe capable of being used in optogenetics, said method comprising:

providing a base region within which there are connection points which are capable of connecting to other electrical components;

providing an integrated elongate probe with a distal tip extending from the base region;

providing a light emitter located in the region of the distal tip of the integrated elongate probe; and

providing an integrated detector.

The method may manufacture an integrated light emitting neural probe as defined in the first aspect.

A substrate may be used to form the neural probe which may be GaN and other similar materials such as InGaN, GaP or GaAs on a suitable carrier. The substrate will typically be of a flat planar structure.

The process of forming the neural probe may be as follows. The substrate may initially be cleaned using, for example, a solvent and then deoxidised using, for example, HCl:H₂O. A layer of metal may then be deposited onto the substrate using, for example, an evaporation technique. The layer of metal may be formed from, for example, Ni and Au. In a particular embodiment the metal layer may be 7 nm of Ni and 14 nm of Au. A photolithography pattern may then be used to form a p mesa pattern. An etching process may then be performed where reactive ion etching (RIE) photolithography may be used to etch the areas of the metal layer away from the p mesa structure. An inductive coupled plasma (ICP) etching process may then be used to etch the areas of the substrate away from the p mesa layer to form mesa. The photoresist p mesa layer may then be removed using solvents. A deposition of a plasma enhanced chemical vapour deposition (PECVD) layer in the form of an oxide layer such as silicon oxide layers may then occur. The PECVD layer may have a thickness of about 350 nm. The PECVD layer may then be roughened using an etching process such as, for example, an Ar RIE plasma etch. A photolith patterning and wet etch process may then be performed to open n and p contact windows. Finally, there may then be a deposition of interconnect layers in the n and p contact windows and along part of the etched substrate area.

According to a third aspect of the present invention there is provided use of the integrated light emitting neural probe defined in the first and second aspects in optogenetics.

According to a fourth aspect of the present invention there is provided an integrated light emitting medical device capable of being used in optogenetics, said integrated light emitting medical device comprising:

a base region within which there are connection points which are capable of connecting to other electrical components;

extending from the base region there is an integrated elongate probe with a distal tip;

one or more light emitters located in the region of the distal tip of the integrated elongate probe; and

one or more integrated detectors.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings in which:

FIGS. 1 and 2 are side views of an integrated light emitting medical device according to an embodiment of the present invention;

FIGS. 3 to 12 represent the basic process for forming an integrated light emitting medical device according to an embodiment of the present invention;

FIG. 13 is a side sectional view of an individual probe and sensor pair according to a further embodiment of the present invention;

FIG. 14 is an upper face view of the individual probe and sensor pair shown in FIG. 13;

FIG. 15 is a lower face view of the individual probe and sensor pair shown in FIGS. 13 and 14; and

FIG. 16 is a view of a further integrated light emitting medical device according to the present invention.

BRIEF DESCRIPTION

Generally speaking, the present invention resides in the provision of medical devices such as neural probes made from an integrated light emitter and detector. There may be one or more light emitters and one or more detectors on the neural probes. The neural probes in contrast to prior art devices comprise a probe structure and emitter in an integrated solid state construction. As will be set out below this provides a number of significant technical advantages.

FIGS. 1 and 2 are side views of an integrated light emitting medical device in the form of a neural probe generally designated 10. The neural probe 10 has the general shape of a needle-like probe and may be formed from a variety of structures such as gallium nitride on a silicon carrier or gallium nitride on a sapphire carrier. Alternatively, the probe structure may also be made from indium gallium arsenide and/or aluminium gallium arsenide diode structure supported by a sapphire, silicon or other similar carrier. Other suitable materials are InGaN, GaP InP, AlGaInP, GaAs or similar compound semiconductor material. The shape of the neural probe 10 may, for example, be cut from a sapphire or silicon carrier using a laser cutting tool.

By selection of the appropriate gallium nitride material or colour changing medium the output wavelength can be accurately defined for each application. The emitter structure may also be shaped to allow collimation, focussing or another means to increase the light emission extraction. The substrate may also carry sensing elements integrated into the probe and formed at predetermined gaps from the emitter. Multiple emitters and sensor probes may also be constructed at predetermined gaps on a single probe. Emitters of differing wavelengths are also possible through material selection or other means.

FIGS. 1 and 2 show that the neural probe 10 has a base region 16 within which there are connection points 12, 14 which are capable of connecting to other electrical components. There may be any suitable number of connection points. Extending from the base region 16 there is an elongate probe 18 with a distal tip 22. The elongate probe 18 may have any appropriate length such as about 100 mm. Located towards the end of the distal tip 22 there is an LED 20 which is capable of emitting light. FIGS. 1 and 2 also show that there is electrical circuitry 24, 26 connecting the LED 20 to the connection points 12, 14. It should be noted that the neural probe 10 may be of any suitable shape where the neural probe 10 is capable of sub-dermal insertion with minimal tissue damage.

The neural probe 10 is designed to integrate single or multi-excitation and single or multi-detection schemes. Furthermore, the nature of the neural probe 10 is designed to reduce detection of artefacts and at the same time to prevent electrical crosstalk and parasitic capacitance effects. This is possible by having a blocking layer which has the dual function of being a ground plane or two layers, one of which is a ground plane. This can be patterned to minimise overlap with the sensing structure and the other layer being an opaque layer. Furthermore, novel lensing or re-direction of the light may be provided to improve directionality of the light to both reduce artefacts and to increase the power density for lower drive currents.

The neural probe 10 also comprises electrodes for sensing which are integrated into the structure. The neural probe 10 may therefore comprise sensing elements. As will be described below the sensing elements may be shielded from direct exposure to the emitting element by a blocking layer. The blocking layer can also be designed to act as a ground plane. A separate ground plane can also be formed and acts to shield from an LED drive. The ground plane may be designed to have an effective area which results in a capacitance of <100 pF. The ground plane can also be designed to have features such as cross-hatch to reduce the plate area and therefore reduce the parasitic capacitance.

FIG. 3 is a representation of a substrate 30 made from, for example, GaN. The substrate has a length of about 100 mm and a thickness such as 0.050 mm to 0.350 mm. The substrate is therefore of a flat planar structure which is initially cleaned using, for example, a solvent and then deoxidised using, for example, HCl:H₂O.

As shown in FIG. 4 a layer of metal 32 is deposited onto the substrate 30 using, for example, an evaporation technique. The layer of metal may be about 2 nm to 20 nm. The layer of metal may be formed from, for example, Ni and Au. In a particular embodiment the metal layer may be 7 nm of Ni and 14 nm of Au.

FIG. 5 then shows that a photolithography pattern is used to form a p mesa pattern 34. The p mesa layer 34 has a thickness of about 2 microns.

FIG. 6 is a representation of an etching process where reactive ion etching (RIE) photolithography is used to etch the areas of the metal layer 32 a, 32 b away from the p mesa structure 34.

In FIG. 7 an inductive coupled plasma (ICP) etching process then occurs which etches the areas 30 a, 30 b of the substrate 30 away from the p mesa layer 34 to form mesa.

FIG. 8 then represents the step where the photoresist p mesa layer 34 is removed using a solvent.

In FIG. 9 there is then a deposition of a plasma enhanced chemical vapour deposition (PECVD) layer 36 in the form of an oxide layer such as silicon oxide layers. The PECVD layer 36 has a thickness of about 350 nm.

In the next step as shown in FIG. 10 the PECVD layer 36 is then roughened using an etching process such as, for example, an Ar RIE plasma etch.

As shown in FIG. 11 there is then a photolith pattern and wet etch process to open n and p contact windows 38, 40.

Finally, FIG. 12 shows that there is the deposition of interconnect layers 42, 44, 46 in the n and p contact windows 38, 40 and along part of the etched substrate area.

FIG. 13 is a side sectional view of an individual probe and sensor pair 50 of the present invention. FIG. 14 is a lower face view of the detector 52 and FIG. 15 is an upper face view of the emitter 54. The individual probe and sensor pair 50 as shown in FIG. 13 has a blocking layer 52 which suppresses Becquerel effects in the sensor array. The blocking layer 52 is shown on the sapphire face. This will have an opening to allow light from the emitter to illuminate the required area while still shielding the sensor metal from direct light exposure. The blocking layer may be composed of, but is not restricted to aluminium. A metallic layer can be used in order to shield the sensor array from parasitic capacitance effects from pulsed switching of the LED. In one embodiment the ground plane may be constructed as a lattice or a grid in order to minimise overlapping area and unwanted capacitance. In this case there should be a supplementing optical blocking layer. An opaque polymer such as but not limited to modified polyimide may be used to supplement or replace the blocking layer in some embodiments. In this case care must be taken in the layout to avoid overlapping feed and sensor tracks to minimise stray capacitance.

An oxide layer or similar electrically insulating layer can be used to encapsulate the blocking layer and isolate it from the sensor array. Sensor metal arrays are defined on top of the insulating layer. The sensor metal can be, but is not restricted to iridium, gold, platinum or titanium or a combination of metals. While biocompatible metals should be chosen, it is also possible that the sensor array may be encapsulated with a biocompatible material such as, but not restricted to silicon nitride or polyimide. In this case the sensor recording sites should be exposed using an appropriate lithographic process.

In one embodiment the recording sensors are formed as a ring structure surrounding the emission source but shielded from the source by the blocking layer. In this configuration the sensor surface is arranged in order to have practically uniform illumination over the entire surface for more accurate results. The area of the sensor element and the underlying insulation material should be selected with appropriate values to match the input impedance requirements of the recording device.

FIG. 16 is a view of a further integrated light emitting medical device 60 of the present invention where there is a ring configuration and four sensor sites 62, 64, 66, 68.

Whilst specific embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the present invention. For example, any suitable type of material may be used to form the integrated light emitting medical devices and any suitable manufacturing process may be used.

In all embodiments, multiple emitter sites and multiple sensor sites may be incorporated in one probe. 

1. An integrated light emitting neural probe, said integrated light emitting neural probe comprising: a base region within which there are integrated connection points which are capable of connecting to other electrical components; extending from the base region there is an integrated elongate probe with a distal tip; a light emitter located in the region of the distal tip of the integrated elongate probe; and an integrated detector.
 2. An integrated light emitting neural probe according to claim 1, wherein the probe is capable of being used in optogenetics; and wherein the integrated light emitting neural probe comprises at least one integrated light emitter and detector.
 3. (canceled)
 4. An integrated light emitting neural probe according to claim 1, wherein the integrated light emitting neural probe has the general structure of a needle-like probe which is capable of sub-dermal insertion with minimal tissue damage; and wherein the needle-like probe is formed by polishing a substrate, locally ablating a substrate surface with a laser, or using wet or chemical etching of a substrate surface.
 5. (canceled)
 6. An integrated light emitting neural probe according to claim 1, wherein the integrated light emitting neural probe is formed from gallium nitride on a silicon carrier or gallium nitride on a sapphire carrier; and wherein the light emitting neural probe comprises an indium gallium arsenide and/or aluminium gallium arsenide diode structure supported by a sapphire, silicon, insulating dielectric or compound semiconductor carrier.
 7. (canceled)
 8. An integrated light emitting neural probe according to claim 1, wherein the shape of the integrated light emitting neural probe is cut from sapphire using a laser cutting tool; and wherein the light emitter is shaped to allow collimation, focussing or another means to increase the light emission extraction.
 9. (canceled)
 10. An integrated light emitting neural probe according to claim 1, wherein a substrate which is used to form the integrated light emitting neural probe also comprises sensing elements integral to the probe formed at predetermined gaps from the light emitter; and wherein multiple emitters and sensor probes are constructed at predetermined gaps on a single probe.
 11. (canceled)
 12. An integrated light emitting neural probe according to claim 1, wherein emitters of differing wavelengths are present through selection of material or other means; and wherein the integrated elongate probe has any appropriate length such as about 20-500 mm or about 100 mm.
 13. (canceled)
 14. An integrated light emitting neural probe according to claim 1, wherein the light emitter is located towards or on the distal tip; and wherein the light emitter is an LED.
 15. (canceled)
 16. An integrated light emitting neural probe according to claim 1, wherein there is a plurality of LED's located on the integrated elongate probe; and wherein the nature of the neural probe is designed to integrate single or multi-excitation and single or multi-detection schemes.
 17. (canceled)
 18. An integrated light emitting neural probe according to claim 1, wherein the nature of the neural probe is designed to reduce detection of optical artefacts and at the same time to prevent electrical crosstalk and reduce parasitic capacitance between the detector and the ground; and wherein there is an optical blocking layer which has the dual function of being a ground plane or two layers, one of which is a ground plane.
 19. (canceled)
 20. An integrated light emitting neural probe according to claim 1, wherein the neural probe also comprises electrodes for sensing which are integrated into the structure; and wherein the sensing elements are shielded from direct exposure to the emitting element by a blocking layer.
 21. (canceled)
 22. An integrated light emitting neural probe according to claim 20, wherein a separate ground plane is also formed and acts to shield the detector signals from an LED drive signal, wherein there is a blocking layer which is designed to have a thickness where the dielectric value minimises the parasitic capacitance between the detector circuit and ground; and wherein there are sensing elements which are designed to reduce electrical cross talk and parasitic capacitance effects and wherein the sensing elements are at discrete sites placed at a known distance from the source. 23.-24. (canceled)
 25. An integrated light emitting neural probe according to claim 1, wherein there are sensing elements which are ring shaped detectors surrounding the source in order to ensure uniform detection and reduce capacitance by having a smaller area, allowing higher packing density; and wherein the emission wavelengths are about 300-1500 nm and preferably about 470 nm for optogenetic stimulation.
 26. (canceled)
 27. An integrated light emitting neural probe according to claim 1, wherein the emission wavelengths are about 300-1500 nm and preferably about 590 nm for optogenetic inhibition; wherein the probe structures are encased in silicon nitride/silicon dioxide films or another suitable material or biocompatibility; and wherein the light emitter includes a lens or other device to collimate the light output. 28.-29. (canceled)
 30. An integrated light emitting neural probe according to claim 1, wherein the LED structure includes an emitter shape to increase the light extraction efficiency; wherein the neural probe comprises an optical blocking layer which is capable of suppressing induced cross-talk effects such as the Becquerel effect in a sensor array; and wherein the blocking layer is composed of aluminium. 31.-32. (canceled)
 33. A method of manufacturing an integrated light emitting neural probe capable of being used in optogenetics, said method comprising: providing a base region from a substrate within which there are connection points which are capable of connecting to other electrical components; providing an integrated elongate probe with a distal tip extending from the base region; providing a light emitter located in the region of the distal tip of the integrated elongate probe; and providing an integrated detector.
 34. A method of manufacturing an integrated light emitting neural probe according to claim 33, wherein the substrate used to form the neural probe is GaN; wherein the substrate is initially cleaned using a solvent and then deoxidized using HCI:H₂O; and wherein a layer of metal such as Ni and Au is deposited onto the substrate using an evaporation technique. 35.-36. (canceled)
 37. A method of manufacturing an integrated light emitting neural probe according to claim 33, wherein a photolithography pattern is used to define a p mesa structure; and wherein an etching process is performed where reactive ion etching (RIE) photolithography is used to etch the areas of the metal layer away from the p mesa structure.
 38. (canceled)
 39. A method of manufacturing an integrated light emitting neural probe according to claim 33, wherein an inductive coupled plasma (ICP) etching process is used to etch the areas of the substrate away from the p mesa layer to form mesa; wherein the photoresist p mesa layer is then removed; and wherein there is then a deposition of a plasma enhanced chemical vapour deposition (PECVD) layer in the form of an oxide layer of silicon oxide layers. 40.-41. (canceled)
 42. A method of manufacturing an integrated light emitting neural probe according to claim 19, wherein the PECVD layer is roughened using an etching process e.g. an Ar RIE plasma etch; wherein a photolith patterning and wet etch process is then performed to open n and p contact windows; and wherein there is a deposition of interconnect layers in the n and p contact windows and along part of the etched substrate area. 43.-46. (canceled) 